For a few months now, my 98 Dyna would sometimes backfire when I'm trying to start it. The backfire would cause a loud bang sound from (I assume) the primary area, and the engine would not start. But I'd hit the starter button again, and it would fire up fine. Note that the backfire / bang usually only happened when cold.

The last week or so, a new problem has cropped up which may be related -- now, if it doesn't start on the first hit of the button, the starter motor just spins and doesn't engage. The first time I hit it, it will turn the engine over, but if it fails to start on that first attempt, it can take 2, 3, 4 or more attempts where the starter motor will just spin without cranking the engine.

I'm thinking solenoid or jackshaft, or perhaps the overrunning clutch, but anyone else ever have this problem?

 

Have you drained the primary oil? Almost sounds to me like your starter gear has lost a few teeth and the jackshaft is free wheeling in the gap left on the starter gear. The loud bang could have been the jackshaft engaging and then breaking the starter gear teeth. I would drain the primaryoil (looking for any debris on the magnetic plug and in the oil),open the primary inspection cover and have a good look around as a first start.

 

So now I can answer my own question. I took out my starter motor on Monday, and found that the planetary gearset, aka "the starter clutch" (a one way overdrive clutch) was stripped. So the starter motor turned, but the gear on the jackshaft that engages the clutch gear ring wouldn't turn. Apparently this is somewhat common. So i didn't need to replace the whole starter, just this starter clutch piece. It presses into a housing, which is bolted to the starter -- and once I got it back in the bike, it started perfectly.

The job is easy, but takes a bit of time because I needed to remove the exhaust to get clearance on the starter, and I removed the primary cover -- although I found out I really didn't have to do that, but it was a good opportunity to check the primary chain, the compensating sprocket, clutch, clutch sprocket -- and change the primary fluid.

Dyna98Mike

 

Wanted to bring this to the top cause sounds like the same thing happened with my 96 wide glide today[:@]!
Motor nice and warm, stopped for a smoke ( I know), and the starter motor just spins. Maybe 10-12 times before it turns over the motor.
Got the bike home in it's bedroom, and it started 3 times in a row on the first hit of the starter.
Does it sound like the same problem as "meveratt", and should my starter motor come out without removing the primary?

THX in advance.... Ben.

 

Hi Ben

From my experience, it sounds like you have the same problem as me. My problem started out as intermittent, then one day it was completely shot.

Actually there are a couple of possibilities. Here's what I did: drained and removed the outer primary cover. Once that's off, you can see the gear that's supposed to pop out and drive the toothed ring on the clutch. On mine, the gear would pop out, but it wouldn't turn. I could hear the starter motor spinning though. What that told me was that the starter motor itself was OK, as was the solenoid. But the planetary gearset (aka the "starter clutch") was shot. I suppose in hindsight, I could have left the primary cover on, as I didn't need to remove it to remove the starter motor -- but without seeing it fail to turn, I might have not known what to replace.

Anyway, to remove the starter motor, you need to remove the exhaust. So make sure you pick up new exhaust gaskets -- theyre cheap. Disconnect the battery first. Then, once the exhaust is out, disconnect the wires to the starter, and remove it -- its held in with two allen bolts. The starter comes apart, you just need to remove the planetary starter clutch housing, and you'll see the offending part. It should free-wheel in one direction, and turn the shaft in the other direction. Mine went both directions, but didn't turn the shaft. Its about $100 US, and needs to be pressed into the housing. Don't lose the other parts! Also, there is a ball bearing inside the jackshaft
which doesn't come in the new part -- you need to tap that ball out and move it to the new shaft.

If you have the shop manual, it shows an exploded view of the entire starter. Good to have!

Anyway, the job is easy, the hardest part was getting the pipes back on. (suggest you get help for that) Good luck.

Mike

 

Finally got around to pulling the starter motor today. Removed the battery and box rather than the pipes, and plenty of room to remove the starter. Nothing obviously screwed in there, but I'll clean it up and replace the clutch and hope for the best. THX for your help.

Cheers... Ben.

 

The starter clutchbreak downis a pretty common problem on the Evo's. Been throught it a couple times on my 89. Sounds exactly like your problem tho. GL...Redd

 

Im having the same problem as meveratt on my wifes 1996 Heritage Softail. I guess ill remove the starter and replace the clutch. Im glad I read these posts. I can get the starter clutch from J&P Cycle for $59.00